Welding oboanization



Dec. 21, 1943. E F, NE SON Re. 22,411

WELDING ORGANIZATION Original Filed April 1, 1940 :E'IELl :EIEZ.

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lNVENTOR EQWARD F. NELSON rma X W m ATTORNEY Reiaued Dec. 21, 1943'WELDING ORGANIZATION Edward F. Nelson, San Leandro, Calif.

Original No. 2,268,416, dated December 30, 1941, Serial No. 327,240,April 1, 1940. Application for reissue September 2, 1942, Serial No.457,093

7 Claims.

This invention relates to the electric buttwelding of stud-like membersto surfaces of metallic objects.

In attaching a stud or other rod-like member to the surface of a metalobject, it is the most accepted practice to connect the metal object andthe stud in series relation in an electric welding circuit, create anelectric arc discharge between an end of the stud and an area of themetal object, to which the stud is to be attached, bring both the end ofthe stud and the said area of the metal object to proper fusiontemperature. and then bring the molten portions of the stud and objecttogether so that they are bonded together. f

Some metals will readily unite and form a desirably strong bond whenwelded in this manner while others require the used a flux which must beintroduced or previously placed between the surfaces to be joined sothat the proper weld maybe obtained. This flux, which is usually apowdered mineral substance, is generally placed in a small pile, on andcoincident with the area of the metal object to which the end of thestud is to be welded. The stud is then placed directly above the fluxand the welding arc is created, the flux being thus within thearc flame.However, this procedure may be employed only when the surface of themetal object is so nearly horizontal that the pile of powdered fluxmaterial will remain intact. It is, of course, obvious that when a studis to be welded to a vertical surface this method of fluxing would beimpractical. There is also another, undesirable feature inherent in themethod of fluxing just described and that is should there be anyspattering of the molten metal during the time that the arc is burning,possibly an excessive amount of the fluxing material may be blown fromthe arc gap so that the resulting weld is seriously weakened. Theinvention, which will now be described in detail has as its objects theprovision of means, associated with the stud to be welded either to ahorizontal or vertical surface, for maintaining. during the weldingoperation, a quantity of flux in proper relation to the electrodesbetween which the arc flame is burning, and the further provision ofshielding means for preventing spattering of the molten metal of theweld when the stud is plunged against the surface of the object to whichit is being welded.

In the drawing:

Figure 1 is a longitudinal vertical sectional view. partly in sideelevation, showing the improved stud and shield of my invention mountedon the chuck of an electric welder.

Figure 2 is a top plan view of the structure shown in Figure 1 showingthe shield retracted to show the end of the stud.

In detail, I have shown achuck, such as forms part of a stud weldingapparatus of the type dischuck may be moved toward and from the surfaceof a metallic object. The other end of the body 3 is provided with anintegral sleeve 6 which is provided with a concentric recess 1 and withaxially extending saw slots 8 which divide the sleeve into a pluralityof resiliently flexible fingers 8. The stud I I, which is to bebutt-welded to the surface of a metallic object, not shown, has one endthereof inserted in the recess I and is frictionally retained therein bythe radial pressure of the fingers 9. The other end of the stud, betweenwhich and the surface of the metallic object the electric arc is struck,is provided with a counterbored recess if having a peripheral bead IS. Ahemispherical hollow shell ii, of relatively thin metal, has its rimpositioned within the recess l2 and the bead I3 is spun over so as toengage the shell and securely fasten the latter to the end of the stud.The shell 16 forms, in conjunction with the bottom surface of the recessI2, a hollow chamber in which fluxing material such as silicon, amixture of iron and aluminum filings, or other such substances, may

be placed. The fluxing material will thus be maintained. in correctrelation to the end of the stud and the welding arc regardless ofwhether the stud is to be welded toa surface in axially vertical orhorizontal positions.

Concentric with and slidable axially of the stud II is a ferrule l8,composed of lava, compressed fire clay or the like electricallynon-conductive heat resistant material, having, in the end thereofcoinciding with the end of the stud, a counterbore 19 and at theopposite end a grooved shoulder 2| to which one end of a coil spring 22is secured. The spring 22 is a snug fit on the sleeve 6 although it may,by the exertion of manual pressure. be slid axially of the sleeve asshown in Figure 2 so as to fix the position of the ferrule 18 relativeto the end of the stud. In its operative position, the end of the studcoincides with that of the ferrule as shown in Figure 1. The

counterbore 18 thus forms a pocket or cup about the end of the stud.When the electrically charged stud and the surface of the metal objectare brought into contact and then immediately separated, an electric arcwill burn between the end of the stud and the adjacent area of theobject surface. This will melt the shell IS, the

fluxing material I1 and the metal at the end of the stud. It will beseen that the cup surrounding the end of the stud will prevent anappreciable amount of themolten material from falling out of the arc gapwhen the stud is being welded in an axially horizontal position. It willalso be seen that when the molten end of the stud is thrust into the arccrater in the surface of the metal object, the ferrule la, in beingbrought before the latter is engaged by .the stud forms an enclosureabout the crater which limits radial sputtering of the molten metal tothe diameter of the counterbore I9. A majority of the metal is thusconfined closely adjacent the junction of the stud with the object withthe result that a weld of maximum strength is obtained. After thewelding current has been turned off and the weld has solidified, theaction of drawing the chuck body 3 axially of the stud away from thesurface of the metal object, will pull the end of the stud out ofengagement with the holding fingers 9 and through the bore of theferrule I8, the latter remaining connected with the chuck body by meansof the 'spring 22, A fresh stud may now be mounted in the chuck, the endof the ferrule l8 aligned with the end of the stud, and the weldingoperation proceeded with as has been described above.

I claim:

l. A rod-like member having a recess in an end thereof, a quantity ofweld-fluxing material in said recess, a thin shell in and closing saidrecess, and a portion of said rod-like member overlying said shell forholding the shell in said recess.

2. A rod-like member having a recess in an end thereof provided with amarginal head, a quantity of weld-fiuxing material in said recess, athin metallic shell in and closing said recess, and said marginal beadbeing bent to a position overlying said shell for securing said shell insaid recess.

3. A ferrule for use in welding a stud to a plate, comprising a sleeveof refractory material having a bore therethrough slightly larger thanthe stud and sufhciently long to provide a stable sliding bearing on thestud to permit movement thereon for seating the ferrule against theplate to closely confine the molten material present between the studand plate. during the welding process. I

4. A ferrule for use in welding a stud to a plate, comprising a sleeveof refractory material having I a'bore therethrough slightly larger thanthe stud I and sufllciently long to provide a stable sliding intoengagement with the said surface slightly bearing on the studto permitmovement thereon for seating the ferrule against the plate, that part ofthe opening surrounding the welding end of the stud being materiallylarger than the remainder of the opening but restricted enough for thesurrounding wall to confine the products of the welding heat closelyabout the end of the stud. 5. A ferrule for use in welding a stud to aplate, comprising a sleeve of refractory material having a boretherethrough slightly larger than the stud and sufficiently long toprovide a stable slidin bearing on the stud to permit movement thereonfor seating one end of the sleeve against the plate, the other end ofthe sleeve having means engageable with a spring for pressing theferrule against the plate. v

6. A ferrule foruse in welding a stud to a plate,

comprising a sleeve of refractory material having a bore therethroughslightly larger than the stud and sufliciently long to provide a stablesliding bearing on the stud to permit movement thereon for seating oneend of the sleeve against the plate, the other end of the sleeve havingan annular shoulder.

'7. A ferrule for use in welding a stud to a plate, comprising a sleeveof refractory material having a bore therethrough slightly'larger thanthe stud and sufllciently long to provide a stable sliding bearing onthe stud to permit movement thereon for seating the ferrule against theplate, that part of the opening surrounding the welding and of the studbeing materially larger than the remainder of the opening and theopposite end of the sleeve having an external annular shoulder.

EDWARD ,F. NELSON.

